FIELD OF THE INVENTION
[0001] The present disclosure relates generally to clinching machines and more particularly
to a hand-held clinching machine.
TECHNICAL BACKGROUND
[0002] It is known to use a clinching machine having a punch and an opposed die for creating
a clinch joint between sheet metal workpieces. Most conventional clinching machines
are stationarily mounted to a factory floor or fixture, but their full clinching cycle
is too slow for creating multiple adjacent clinch joints quickly with a single tool.
[0003] Some traditional hand-held clinching tools have been used. Hand-held examples are
disclosed in:
U.S. Patent No. 4,878,284 entitled "Hand Held Sheet Metal Joining System" which issued to Sawdon on November
7, 1989;
U.S. Patent No. 5,642,559 entitled "Portable Sheet Material Joining Tool" which issued to Sawdon on July 1,
1997; and
U.S. Patent No. 5,806,362 entitled "Method and Apparatus for Carrying Out An Operation on a Mechanical Workpiece"
which issued to Dubugnon on September 15, 1998; which are all incorporated by reference
herein. The commercial version of the Dubugnon hand-held clinching tool has employed
a U-shaped, small and multi-piece handle which is very uncomfortable for a user to
hold, since it is difficult if not impossible to fit the entire user's hand therein.
Furthermore, the commercial version of the Dubugnon hand-held units have difficult
to activate manual switches as well as other mechanical protuberances which are prone
to snagging on workpieces and make it difficult to access desired joint locations
for workpieces with multiple offset surfaces.
SUMMARY OF THE INVENTION
[0004] In accordance with the present invention, there are provided a clinching machine
and method for using a clinching machine as defined in the appended claims.
[0005] In another aspect, a hand-held clinching machine and method employ a movable jaw,
a cam wedge, and a rocker arm to control opening and closing movement of the clinching
jaw. Another aspect of a clinching machine and method includes a movable clinching
jaw, a fluid activated piston, a manually actuated switch which causes fluid actuated
rotation of a lever, a manually actuated trigger to fluidically advance a piston and
a block attached to a forward end of a piston rod, and an abutting stop surface movable
with the movable jaw, where the stop surface abuts against the lever in an operating
condition to limit opening rotation of the movable jaw to an intermediate position
between a fully open position and a fully closed and clinching position.
[0006] According to another aspect, there is disclosed a clinching machine comprising:
- (a) a piston cylinder;
- (b) a piston moveable within the cylinder;
- (c) multiple jaws, at least one of which is moveable relative to the piston cylinder;
- (d) a workpiece clinching punch mounted to one of the jaws;
- (e) a workpiece clinching die mounted to another of the jaws;
- (f) a cam moveable with the piston, between a retracted position and an advanced position,
to cause opening and closing of the at least one moveable jaw, the cam being located
between portions of the jaws when the cam is in at least of its positions; and
- (g) a rocker arm rotatable about a pivot from a first rocking orientation to a second
rocking orientation independent of movement of the cam, the first rocking orientation
allowing the at least one moveable jaw to move to a fully open position, and the second
rocking orientation allowing the at least one moveable jaw to move to an intermediate
open position which is less than the fully open position.
[0007] Additional features of such clinching machine, taken alone or in combination, are
the following:
- the clinching machine further comprises a fluid-operated moving jaw position valve;
a user-activatable, upper jaw position actuator openly actuating the moving jaw position
valve; and a spring opening the at least one moving jaw to the intermediate open position
when the moving jaw position valve rotates the rocker arm to the second rocking orientation.
- the clinching machine further comprises a user-activatable trigger; a main power switch,
actuated by the trigger, causing fluid to advance the piston and the cam which rotates
the at least moveable jaw toward the opposite jaw to create a workpiece clinch joint;
a cam follower coupled to the moveable jaw; and the cam being a wedge block with a
peripheral camming surface against which the cam follower rides.
- the clinching machine further comprises a ring located between the jaws on one side
and the piston cylinder on an opposite side; a single piece and entirely polymeric
handle coupled to the ring, the handle having a curved D-shape; and a user-operable
trigger coupled to the ring opposite the handle; wherein the clinching machine is
hand-held and portable.
- the rocker arm is a lever including a forward end operably abutting a stop extending
from the at least one moveable jaw, and a rearward end coupled to a fluid actuator
located between the piston and the jaws; a pivot of the rocker arm is between the
ends of the rocker arm; and axes of the rocker arm and a rotational pivot coupling
the jaws, are parallel.
- the clinching machine further comprises a hand-held spine; one of the jaws operably
rotating while an opposite of the jaws being stationary relative to the piston cylinder;
the die being mounted adjacent a forward end of the stationary jaw and the punch being
mounted adjacent a forward end of the moveable jaw; the stationary jaw being coupled
to a forward end of the spine and the piston cylinder being coupled to a rearward
end of the spine; an enclosed user-graspable handle coupled to the spine and the stationary
jaw, the handle being wider than an exterior surface of the piston cylinder; a piston
rod being linearly moveable within the spine; a user-operable trigger and an enclosed
trigger guard coupled to the spine opposite the handle; and the pivotable rocker arm
being located between the forward end of the spine and a rotational coupling between
the jaws.
- the clinching machine further comprises a moveable tail coupled to an end of the moveable
jaw opposite the punch; a cam follower coupled to the tail and operably contacting
against the cam when the cam is advanced to rotate the moveable jaw to a closed and
workpiece clinching position; and a pin including an offset lobe which is rotatable
to adjust an orientation of the tail relative to the moveable jaw.
- the clinching machine further comprises a piston return spring partially located with
an elongated and hollow spine, the spine extending between the piston cylinder and
a gimble ring assembly to which at least one of the jaws is coupled; a channel extending
along a length of the spine; and a pneumatic tube routed in the channel.
[0008] According to another aspect, there is disclosed a clinching machine comprising:
- (a) a piston cylinder;
- (b) a piston moveable within the cylinder;
- (c) multiple jaws, at least one of which is moveable relative to the piston cylinder;
- (d) a workpiece clinching punch mounted to one of the jaws;
- (e) a workpiece clinching die mounted to another of the jaws;
- (f) a camming wedge moveable with the piston, between a retracted position and an
advanced position, to cause opening and closing of the at least one moveable jaw,
the camming wedge being located between portions of the jaws when the camming wedge
is in at least one of its positions; and
- (g) a moveable tail coupled to an end of the moveable jaw opposite the punch;
- (h) a cam follower coupled to the tail and operably contacting against the camming
wedge when the wedge is advanced to rotate the moveable jaw to a closed and workpiece
clinching position; and
- (i) a pin including an offset lobe which is rotatable to adjust an orientation of
the tail relative to the moveable jaw.
[0009] Such clinching machine may further comprises a hand-held spine; one of the jaws operably
rotating while an opposite of the jaws being stationary relative to the piston cylinder;
the die being mounted adjacent a forward end of the stationary jaw and the punch being
mounted adjacent a forward end of the moveable jaw; the stationary jaw being coupled
to a forward end of the spine and the piston cylinder being coupled to a rearward
end of the spine; an enclosed user-graspable handle coupled to the spine and the stationary
jaw, the handle being wider than an exterior surface of the piston cylinder; a piston
rod being linearly moveable within the spine; a user-operable trigger and an enclosed
trigger guard coupled to the spine opposite the handle; and a pivotable rocker arm
being located between the forward end of the spine and a rotational coupling between
the jaws.
[0010] According to another aspect, there is disclosed a clinching machine comprising:
- (a) an actuator;
- (b) multiple jaws, at least one of which is moveable relative to the actuator;
- (c) a workpiece clinching punch mounted to one of the jaws;
- (d) a workpiece clinching die mounted to another of the jaws;
- (e) a user-moveable trigger operable to cause the actuator to move the at least one
jaw from a fully open position to a workpiece-clinching position; and
- (f) a user-moveable button operable to limit opening of the at least one jaw to an
intermediate open position which is less than the fully open position.
[0011] Additional features of such clinching machine, taken alone or in combination, are
the following:
- the clinching machine further comprises a cam moveable with the actuator, between
a retracted position and an advanced position, to cause opening and closing of the
at least one moveable jaw, the cam being located between portions of the jaws when
the cam is in at least of its positions; and a rocker arm rotatable about a pivot
from a first rocking orientation to a second rocking, the first rocking orientation
allowing the at least one moveable jaw to move to a fully open position, and the second
rocking orientation allowing the at least one moveable jaw to move to the intermediate
open position.
- the clinching machine further comprises a fluid-operated moving jaw position valve
activated by movement of the button; and a spring opening the at least one moving
jaw to the intermediate open position when the moving jaw position valve rotates the
rocker arm to the second rocking orientation.
- the clinching machine further comprises an elongated spine which couples the actuator
to the jaws; the button being rotatable about an axis which is coaxial with the spine;
and the button and the trigger being located adjacent a forward end of the spine with
the trigger being moveable toward the spine.
- the clinching machine further comprises an intermediate position switch; multiples
of the button being located on a rear face of a rotatable collar, the collar forming
more than a semicircle surrounding a portion of the spine; and a ramp and a detent
depression located on a front face of the collar which operable activate and deactivate
the intermediate position switch.
- the clinching machine further comprises an elongated and hollow, hand-held spine;
one of the jaws operably rotating while an opposite of the jaws being stationary relative
to the actuator; a clinching die mounted adjacent a forward end of the stationary
jaw; a clinching punch being mounted adjacent a forward end of the moveable jaw; a
piston cylinder coupled to a rearward end of the spine and the stationary jaw being
coupled to a forward end of the spine; an enclosed user-graspable handle coupled to
at least one of the spine and the stationary jaw, the handle being wider than an exterior
surface of the actuator; and the user-operable trigger and an enclosed trigger guard
coupled to the spine opposite the handle.
[0012] According to another aspect, there is disclosed a machine comprising:
- (a) a piston cylinder;
- (b) a piston longitudinally moveable within the cylinder;
- (c) multiple jaws, at least one of which being moveable relative to the piston cylinder;
- (d) a workpiece fastening punch mounted to one of the jaws;
- (e) a workpiece fastening die mounted to another one of the jaws;
- (f) a longitudinally elongated spine, the cylinder being coupled adjacent a rear end
of the spine and the jaws being coupled adjacent a front end of the spine;
- (g) a user-grippable housing covering the spine;
- (h) multiple fluid-carrying tubes located between the spine and the housing along
an entire longitudinal distance of a user-grippable area of the housing, at least
one of the tubes being coupled to the cylinder;
- (i) a user-actuable switch located adjacent the front end of the spine; and
- (j) the machine being hand-held and portable.
[0013] Additional features of such machine, taken alone or in combination, are the following:
- the machine further comprises a fluid-operated moving jaw position valve coupled to
at least one of the tubes; and a spring opening the at least one moving jaw to an
intermediate open position, which is less than a fully open position, when the moving
jaw position valve moves an arm which blocks the moving jaw from opening to the fully
open position.
- the machine further comprises a cam; a piston rod coupling the cam to the piston;
a user-activatable trigger; the switch, actuated by the trigger, causing fluid to
advance the piston and the cam which rotates the at least moveable jaw toward the
opposite jaw to create a workpiece clinch joint; the piston rod moveable within a
hollow center of the spine, the tubes being external to the hollow center of the spine;
a cam follower coupled to the moveable jaw; and the cam being a wedge block with a
peripheral camming surface against which the cam follower rides.
- the punch is a sheet metal clinching punch mounted to a rotatable one of the jaws;
the die is a sheet metal clinching die, including a central anvil and moveable die
blades, mounted to a stationary one of the jaws; and the housing is polymeric, elongated
and surrounds the spine.
- the machine further comprises a piston return spring partially located with a hollow
center of the spine; a piston rod linearly moveable within the hollow center of the
spine, the rod being operable driven by the piston; a gimble ring assembly coupled
to at least one of the jaws adjacent the front end of the spine; at least one channel
externally extending along a length of the spine; and the tubes are pneumatic tubes
routed in the at least one channel.
- the machine further comprises a gimble ring assembly coupled to at least one of the
jaws adjacent the front end of the spine; and the tubes extending through an enclosed
internal opening of the gimble ring assembly.
- the machine further comprises a second user-actuable switch coupled to at least one
of the tubes, the second switch being located adjacent the front end of the spine,
at least one of the switches causing at least one of the jaws to move toward the other,
and the other of the switches limiting the at least one moveable jaw to an intermediate
opening position which is less than a fully opening position.
[0014] According to another aspect, there is disclosed a method of using a clinching machine,
the method comprising:
- (a) suspending the clinching machine from an overhead cable;
- (b) manually grasping an enclosed handle of the clinching machine to move the clinching
machine relative to a workpiece;
- (c) rotating a moveable jaw to a fully open position;
- (d) manually actuating a switch to pneumatically rotate a lever between fully open
and intermediate open positions;
- (e) manually actuating a trigger to pneumatically advance a piston and a block attached
to a leading end of a piston rod;
- (f) rotating the moveable jaw to a fully closed and workpiece clinching position in
response to step (e);
- (g) abutting the lever with a stop surface moveable with the moveable jaw to limit
opening rotation of the moveable jaw; and
- (h) rotating the moveable jaw to an intermediate open position which is less than
the fully open position due to step (g).
[0015] Additional features of such method, taken alone or in combination, are the following:
- the method further comprises spring biasing the moveable jaw toward the open positions;
spring biasing the piston toward a retracted position; and placing an entire user
palm inside the handle which is a single piece and entirely polymeric curved handle
of the clinching machine, the handle being on an opposite side of the piston rod from
the trigger.
- the method further comprises manually rotating a shaft to adjust a full opening end
of travel position of the moveable jaw relative to an opposed stationary jaw; a clinching
die mounted to the stationary jaw; a clinching punch mounted to the moveable jaw;
moving a tail coupled to the moveable jaw by adjusting the shaft; and engaging a cam
follower with a camming surface of the block, the cam follower being mounted on the
tail.
[0016] The present clinching machine and method are advantageous over conventional devices.
For example, the present clinching machine and method provide a more cost effective
and smaller package wherein a movable clinching jaw is limited to an intermediate
opening position in one operating condition. This intermediate position makes subsequent
jaw closure much faster to apply multiple clinching joint formations in a very fast
and repeatable manner. Furthermore, the present clinching machine and method are advantageously
easier to adjust a fully open jaw position. The present clinching machine and method
are more cost effective and contained within a smaller packaging space due to all
actuating movement being either pneumatic fluid or spring activated, without electrical
controls or sensors. Moreover, the single piece and polymeric handle aspect of the
present clinching machine and method make user grasping much more comfortable and
less prone to fatigue; thus, much more ergonomical. Additional advantages and features
of the present invention will become apparent from the following description and appended
claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017]
Figure 1 is a front perspective view showing the present clinching machine;
Figure 2 is a side elevational view showing the present clinching machine;
Figure 3 is a top elevational view showing the present clinching machine;
Figure 4 is a rear perspective view showing the present clinching machine, with external
housings removed;
Figure 5 is a partially exploded, rear perspective view showing the present clinching
machine, with central and forward external housings removed;
Figure 6 is an exploded, front perspective view showing a jaw assembly of the present
clinching machine;
Figure 7 is an exploded, front perspective view showing a piston assembly of the present
clinching machine;
Figure 8 is an exploded, front perspective view showing an intermediate work position
cylinder assembly of the present clinching machine;
Figure 9 is a cross-sectional view, taken along line 9-9 of Figure 5, showing the
intermediate work position cylinder assembly of the present clinching machine, in
an advanced position;
Figure 10 is a cross-sectional view, taken along line 9-9 of Figure 5, showing the
intermediate work position cylinder assembly of the present clinching machine, in
a retracted position;
Figure 11 is an exploded, rear perspective view showing a pivot ring assembly of the
present clinching machine;
Figure 12 is a side elevational view showing the present clinching machine, with the
central and forward housings removed, and with jaws in a closed and workpiece clinching
position;
Figure 13 is a side elevational view showing the present clinching machine, with the
central and forward housings removed, and with the jaws in a fully open position;
Figure 14 is a side elevational view showing the present clinching machine, with the
central and forward housings removed, and with the jaws in an intermediate open position;
Figure 15 is a side elevational view, opposite that of Figure 12, showing the present
clinching machine in the jaw closed position;
Figure 16 is a cross-sectional view, taken along line 16-16 of Figure 3, showing the
present clinching machine, with the jaws in the closed position;
Figure 17 is a cross-sectional view, taken along line 16-16 of Figure 3, showing the
present clinching machine, with the jaws in the fully open position;
Figure 18 is a cross-sectional view, taken along line 16-16 of Figure 3, showing the
present clinching machine, with the jaws in the intermediate open position;
Figure 19 is a diagrammatic cross-sectional view showing clinching tools of the present
clinching machine, in an initial workpiece contacting condition;
Figure 20 is a diagrammatic cross-sectional view showing the clinching tools of the
present clinching machine, in a mid-workpiece clinching condition;
Figure 21 is a diagrammatic cross-sectional view showing the clinching tools of the
present clinching machine, in a fully clinch-forming condition;
Figure 22 is a front perspective view showing pneumatic tube routing at the piston
assembly of the present clinching machine;
Figure 23 is a rear perspective view showing the pneumatic tube routing at the pivot
ring assembly of the present clinching machine;
Figure 24 is a front perspective view showing the pneumatic tube routing at the jaw
assembly of the present clinching machine;
Figure 25 is a front perspective view showing the piston assembly of the present clinching
machine;
Figure 26 is a diagrammatic view showing a pneumatic circuit diagram of the present
clinching machine;
Figures 27 and 28 are rear perspective views showing a trigger and switch of the present
clinching machine;
Figure 29 is a side elevational view showing a second embodiment of the present clinching
machine;
Figure 30 is a partially exploded, rear perspective view showing the second embodiment
of the present clinching machine;
Figure 31 is an exploded, front perspective view showing the second embodiment of
the jaw assembly of the present clinching machine;
Figure 32 is a cross-sectional view showing the second embodiment of the present clinching
machine, with the jaws in the closed position;
Figure 33 is a side elevational view showing the second embodiment of the present
clinching machine, with the central and forward housings removed, and with the jaws
in the closed and workpiece clinching position;
Figure 34 is a side elevational view showing the second embodiment of the present
clinching machine, with the central and forward housings removed, and with the jaws
in the fully open position;
Figure 35 is a side elevational view showing the second embodiment of the present
clinching machine, with the central and forward housings removed, and with the jaws
in the intermediate open position;
Figure 36 is an enlarged and fragmentary perspective view, taken within circle 36
of Figure 33, showing the second embodiment of the present clinching machine with
an intermediate button in a first position;
Figure 37 is an enlarged and fragmentary perspective view, taken within circle 36
of Figure 33, showing the second embodiment of the present clinching machine with
the intermediate button in an opposite second position;
Figure 38 is an enlarged and fragmentary perspective view, taken within circle 36
of Figure 33, showing the second embodiment of the present clinching machine, with
the central housing removed and the intermediate button in the first position;
Figure 39 is an enlarged and fragmentary perspective view, taken within circle 36
of Figure 33, showing the second embodiment of the present clinching machine, with
the central housing removed and the intermediate button in the second position;
Figure 40 is a partially sectioned, perspective view showing the second embodiment
of the present clinching machine with an intermediate switch in an activated condition;
and
Figure 41 is a partially sectioned, perspective view showing the second embodiment
of the present clinching machine with the intermediate switch in a deactivated condition.
DETAILED DESCRIPTION
[0018] Figures 1-5 illustrate a first exemplary embodiment of a clinching machine apparatus
41 used to create a clinch joint between multiple sheet metal workpieces 43 and 45.
Clinching machine 41 includes a jaw assembly 51 at a forward end, a pivot ring assembly
53 and a piston assembly 55 at a rear end. A pair of polymeric exterior housings 57
sandwich a rear section of jaw assembly 51 and are removeably screwed onto ring assembly
53 and a stationary lower jaw 59 of the jaw assembly.
[0019] Piston assembly 55 includes a structural and central spine 71 to which a pair of
polymeric central housings 73 are removeably screwed. Central housings 73 include
an elongated middle section together creating a generally circular hollow area enclosing
spine 71. Furthermore, laterally projecting leading and trailing sections of central
housings 73 enclose the adjacent circular portions of ring assembly 53 and piston
assembly 55, respectively. A person using or operating the clinching machine grasps
one of his or her hands around central housing 73, which has a curved upper surface
and a diagonally angled lower surface to comfortably conform to the user's palm and
fingers. Moreover, spine 71 is longitudinally elongated with a forward end screwed
to a back face of ring assembly 53, and with a rear end screwed to a front face of
a hollow piston cylinder 75 of piston assembly 55. An elongated and L-shaped polymeric
housing 77 is removably screwed to an exterior side of piston cylinder 75.
[0020] An enclosed polymeric trigger guard 78 is screwed onto ring assembly 53 and piston
cylinder 75. Additionally, a generally D-shaped and entirely enclosed handle 79 is
preferably made as a single piece polymeric member. An interior surface 81 defines
a curved through-opening within which the user can entirely place his or her entire
hand or fingers for handle gripping. A lateral dimension of the handle through-opening
is at least 100 mm at its widest horizontal portion. Furthermore, a flange 83 downwardly
projects from a central and generally flat bottom of handle 79, which is screwed to
the front face of ring assembly 53.
[0021] Handle 79, guard 78 and all of housings 57, 73 and 77 are preferably additively manufactured
by three-dimensional printing polymer layers in a computer controlled three-dimensional
printing ("3DP") machine. An exemplary 3DP machine has a head, with multiple polymer-emitting
nozzles, which slides along a moveable gantry above a machine table in an ambient
air environment. Light sources within the 3DP machine emit light to cure each layer
before the next is added. This 3DP manufacturing advantageously creates the curved
handle without conventional injection molding parting lines otherwise uncomfortable
to the user's hand, and for creating internal ribs and undercuts that would be die-locked
or more expensive to manufacture with injection molding. Nevertheless, injection molding
may alternately be employed although the noted 3DP advantages may not be achieved.
[0022] An L-shaped metallic tab 85 is screwed to an upper section of the front face of ring
assembly 53. An eyelet 87 is mounted to tab 85 and a flexible cable 89 is hooked onto
the eyelet. Cable 89 is hung from an underside of a factory ceiling or structural
beam 91. Thus, portable and hand-held clinching machine 41 is suspended about its
center of gravity, which is approximately at the intersection of spine 71 and ring
assembly 53 for maximum balance. As can be observed in Figure 11, ring assembly 53
includes an internal hub 93 around which is mounted a ball bearing race 95. The front
and back mounting faces are part of or attached to hub 93. An outer ring 97 is rotatably
mounted to hub 93 with ball bearing race 95 therebetween. Ring assembly 53 serves
as both a gimble and a mounting structure. Therefore, handle 79 attached to hub 93,
as well as the affixed jaw assembly and piston assembly, can together be rotated for
ease of access to the workpieces, while outer ring 97 remains suspended from the factory
ceiling.
[0023] Reference should now be made to Figures 6 and 12-16. Jaw assembly 51 includes stationary
lower jaw 59 and a movable upper jaw 101. The jaws are coupled together by a pivot
pin 103 which spans between a pair of bifurcated knuckles 105 upstanding between a
front end 107 and a rear end 109 of lower jaw 59. Furthermore, rear end 109 has an
inverted U-shape with a hollow passageway extending between knuckles 105. A rectangular
key 111 has a lower end received and screwed within a pocket of lower arm 59. Moreover,
an upper end of key 111 is received and screwed within a pocket of pivot pin 103,
thereby preventing pivot pin 103 from rotating. A pair of cam followers 113 and 115,
such as the illustrated rollers journalled about pins 117 and 119, with bearing races
121 therebetween, are span across the hollow passageway and are attached to the spaced
apart side walls of lower jaw 59 by washers 125 and circlip fasteners 127.
[0024] A pair of spaced apart and symmetrical rocker arm levers 131 have a common central
pivot about a reduced diameter pin 133 coaxially projected from an end of roller pivot
pin 119. A forward end of rocker arms 131 has a bushing 135 spanning therebetween
on a pin, and a rearward end of rocker arms 131 also has another bushing 137 spanning
therebetween on a pin.
[0025] A work position pneumatic valve 141 includes a piston rod 143 having an aperture
through which bushing 137 and the associated pin extend. Thus, movement of a piston
145 and the associated rod 143 of valve 141 downwardly push and rotate rocker arms
131 about pivot 133, when valve 141 is actuated. This can best be observed in Figures
6, 9, 10, 12 and 13.
[0026] Returning to Figures 6 and 12-18, a pair of spaced apart and symmetrical tails 151
are adjustably coupled to opposite sides of the rear section of movable upper jaw
101 via a pivot pin 153 and circlips 155 extending through a middle hole in each tail.
A generally cylindrical adjustment shaft 157 includes an enlarged central segment
having an offset lobe 159 extending off of a centerline axis of the shaft. Shaft 157
also has a head 161 with a screw-driver receiving groove or alternately a hexagonal
formation. Lobe 159 is received within a through-slot 163 in upper jaw 101. Hence,
manual rotation of head 161 causes the lobe 159 to slot 163 interaction to rotate
tails 151 about pivot pin 153. This rotates tails 151 relative to upper jaw 101 to
provide adjustment should an intermediate opening position need to be varied for different
thickness workpieces or for different sized clinching tools.
[0027] Another cam follower roller 171 is journalled about a ball bearing race 173 and pin
175. Pin 175 is fastened between holes in a lower segment of tails 151 by circlips
177. Furthermore, an abutment foot 181 is screwed to a side of movable upper jaw 101
and includes a downwardly projecting offset stop 183 which abuts against front roller
135 of rocker arms 131 in an operating condition.
[0028] Clinching tools are mounted in an opposing and aligned manner to jaws 59 and 101.
Referring to Figures 1, 6, 16, 17 and 19-21, the clinching tools include a punch assembly
221 and a die assembly 223. Punch assembly 221 further includes an elongated workpiece
striking punch 225, a generally cylindrical and elastomeric stripper 227 and a punch
holder 229. The punch assembly is preferably mounted adjacent the front end of movable
jaw 101.
[0029] Die assembly 223 includes a die 231 and a die holder 233. Die further has a central
anvil 235 surrounded by laterally movable die blades 237. A cylindrical and elastomeric
band or a canted coiled spring 239 retain and bias die blades 237 toward anvil 235
within a cylindrical outer shield 241. Die holder 233 couples die assembly 223 to
a front end of stationary jaw 59. Exemplary clinching tools are disclosed in commonly
owned
U.S. Patent Nos. 5,208,974 entitled "Apparatus for Attaching a Fastener to Sheet Material" which issued to Sawdon
et al. on May 11, 1993; and
5,727,302 entitled "Die and Punch for Forming a Joint and Method of Making the Die" which issued
to Sawdon on March 17, 1998; both of which are incorporated by reference herein.
[0030] Thus, when moveable jaw 101 is rotated to its closed and clinching position (shown
in Figure 16), punch 225 deforms a round button in the workpieces 43 and 45, between
a lower distal end of the punch and an upper distal end of anvil 235. Concurrently,
the workpieces outwardly rotate the upper ends of the die blades which extend above
the anvil. This creates an interlocking and leakproof clinch joint between the workpieces.
[0031] Figures 7, 14, 18 and 25 illustrate piston assembly 55. A peripherally cylindrical
piston 241 is longitudinally moveable within a chamber internal to hollow and cup
shaped piston cylinder 75. An end cap 243 is screwed onto a rear open section of piston
cylinder 75, and inlet and exhaust pneumatic ports are located therein. A longitudinally
elongated piston rod 245 is attached to a center of piston 241. Moreover, a helically
coiled compression spring 247 surrounds a majority length of piston rod 245 and extends
through an orifice in piston cylinder 75. A front end of spring 247 is located within
a cavity abuts against an internal surface at a front half of spine 71 and a rear
end of spring 247 abuts against a face of piston 241. A camming wedge block 251 is
pinned to a distal end of piston rod 245 and has a camming surface 253 on a peripheral
upper surface thereof. Camming surface 253 is preferably a constantly varying volute
curve which is steeper on a leading section and flatter on a trailing section. Wedge
block 251 further has a forked or multi-angled peripheral front surface and the wedge
block has a longitudinal length at least five times greater than a lateral width.
Also, a peripheral bottom surface of wedge block 251 is essentially flat.
[0032] Reference should now be made to Figures 12, 13, 17 and 22-28 for a pneumatic circuit
employed in the clinching machine. Ends of an air actuation inlet tube 271 and an
air actuation outlet tube 273 are in communication with ports of end cap 243. An opposite
end of inlet tube 271 is in communication with a pneumatic power cycle switch 275.
Switch 275 is mounted to ring assembly 53 beneath spine 71. A finger 277 of switch
275 is depressible by manual upward rotation of a trigger button 279 located on an
opposite side of spine 71 from handle 79. Air is received from switch 275 to end cap
243 in an operating condition.
[0033] A front end of outlet tube 273 is in communication with intermediate work valve 141.
Outlet tube 273 supplies pressurized air to valve 141 in an operating condition. Furthermore,
a median tube 281 is a pneumatic connection between switch 275 and valve 141, whereby
air flows from the valve to the switch in an operating condition. Moreover, another
median tube 283 supplies air from an intermediate work position switch 285 to valve
141 when switch 285 is activated by the user manually rotating a button 287 relative
to ring assembly 53. Button 287 is rearwardly facing and easily accessible through
an opening in the central housing for thumb movement by the user's right hand when
the right hand is grasping around the central housing and an index finger of the user's
right hand may simultaneously depress the trigger.
[0034] The tubes are made from a flexible and polymeric material. Tubes 271 and 273 are
routed in one or more channels along an outside of the end cap, piston cylinder and
spine. This recessed routing prevents the tubes from being pinched when the rear and
central housings 77 and 73, respectively, are installed.
[0035] The clinching machine is operated as follows, with reference to Figures 5, 12-18
and 26. First, movable upper jaw 101 is initially in its fully open positions as shown
in Figures 13 and 17, since air pressure has been released and a tensioning jaw spring
301 rotates upper jaw 101 about the main jaw pivot 103. Second, the user positions
the hand-held clinching machine with the die assembly against an underside of the
adjacent workpiece to be clinched. Third, the operator uses his or her thumb to manually
rotate intermediate work position button 287 which actuates work position switch 285,
which in turn, supplies air to upper arm work position valve C1 and 285. This valve
285 supplies air to valve C2 and 141 for extending piston 145, which downwardly rotates
a rear end of rocker arms 131, such that a front end of the rocker arm upwardly pushes
against abutment stop 183 to rotate upper jaw 101 to an intermediate open position.
This intermediate open position provides a gap of about 6 mm between punch assembly
221 and die assembly 223, as is illustrated in Figures 14 and 18. Valve C1 and 285
passes air to power cycle switch C4 and 275 only when piston 145 is extended. Thus,
the power cycle switch will only operate after this sequence has taken place.
[0036] Fourth, the operator manually rotates trigger C3 and 279 which actuates power cycle
switch 275, which energize an integrated poppet valve C4 built into end cap 243. Fifth,
when the poppet valve opens, the main power cylinder C5 and 75 are pneumatically pressurized
to linearly advance the piston, piston rod and wedge block forward between roller
171 of upper arm on the one side and rollers 113 and 115 on the opposite side. More
specifically, camming surface 253 of wedge block 251 forces upper jaw to rotate toward
the closed and clinching position as can be seen in Figures 12, 15 and 16. This supplies
at least 25 and more preferably 35 kN of clinching force between the punch and anvil.
[0037] Sixth, the moveable upper jaw and rocker arms separate during the power closing cycle
and main return spring 247 retracts the piston, piston rod and camming wedge block
when the trigger is manually released. This allows jaw spring 301 to reopen the upper
jaw to the intermediate position where stop 183 again abuts against front end of rocker
arms 131. Subsequent trigger actuation causes main piston 241 to again advance wedge
block 251 and reclose the clinching tools for faster repeated clinch joint forming
since the jaw does not need to open and close the full rotation were the stop not
to abut against the rocker arm. This action beneficially provides very fast formation
of multiple clinch joints in a "pecking manner" along the same workpiece combination.
[0038] A second exemplary embodiment of a clinching machine apparatus 1041 is illustrated
in Figures 29 - 41. Clinching machine 1041 is used to fasten multiple workpiece sheets,
preferably with a clinch joint. Furthermore, clinching machine 1041 is handheld and
portable for use in quickly creating multiple clinching joints by moving the machine
relative to stationary workpieces, although it is alternately envisioned that the
present machine may be stationary while the workpieces are moved. The second embodiment
is identical to the first embodiment discussed hereinabove except for the following
features.
[0039] As can best be observed in Figures 29 - 32, a handle 1079 is fully enclosed and has
a generally D-shape when viewed from the front or rear, which may be grabbed by a
user's hand inserted therethrough during use of the machine. Handle 1079 has a greater
height dimension H as compared to a slightly smaller dimensioned for-and-aft thickness
T at the top and sides thereof. This achieves a greater handle stiffness in use. Moreover,
a plurality of nodules 1002 project from front and rear faces of handle 1079 to provide
an improved finger interface with the user's hand, thereby deterring slippage when
grasped. Handle 1079 is preferably manufactured by 3D printing but may alternately
be injection molded. Additionally, handle 1079 is preferably made as a single and
integral polymeric piece without a metal core, in order to reduce weight and expense.
[0040] A removable polymeric, front exterior housing 1057 protectively covers sides of a
jaw assembly 1051. Removable polymeric, central housings 1073 protectively cover a
linearly elongated and centrally positioned spine 71 with fluid tubes 271 and 273
linearly extending therebetween. Spine 71 shields the fluid tubes from piston rod
245 which is movable within the spine. This allows easy installation and easy servicing
of the fluid tubes, without exposing the tubes to sharp metal holes in the spine or
adjacent parts.
[0041] Reference should now be made to Figures 31 - 35 to observe the differences to jaw
assembly 1051. First, the second embodiment of a rocker arm 1131 is now of a single
piece with bifurcated forward and rearward ends. Furthermore, an offset stop 1183
is adjustable by employing a downwardly projecting screw 1004 and a nut 1006. Screw
1004 has a lower head which operably abuts against bushing 135 attached to rocker
arm 1131 while a shaft of screw 1004 is threaded for rotational movement within nut
1006 and an aligned bore within the generally L-shaped body of stop 1183. Moreover,
a roller bearing 1103 has been added at main pivot 103 and full complement bearings
have been used at 1121, 1173, 1113, 1115 and 1175. Additionally, a single washer 1125
is employed adjacent rocker arm 1131 and an oil fitting is no longer needed at main
pivot 103. A generally angular fin 1010 projects from a lower edge of tail 1151 for
contact against a side ledge of camming wedge block 251 in certain operating conditions.
[0042] Figures 33 - 41 illustrate an intermediate switch assembly employed with the second
embodiment clinching machine. A collar 1012 has a rear face with a generally frusto-conical
shape and a central opening surrounding a majority (and greater than a semi-circular
portion) of its rotational axis and spine 73. Radial edges 1014 face each other at
a lower section thereof and are spaced apart with trigger 1279 therebetween. User
actuable buttons 1287 project from the rear face of collar 1012 and are accessible
through openings 1016 within a matching generally frusto-conical bell segment of central
housings 73. Thus, the user may engage either his right or left thumb against a side
wall of a radially elongated one of the buttons 1287, while gripping the central housings
with the same hand, to rotate the button approximately 20 - 30 degrees about its rotational
axis. This button and collar rotation will cause an angled ramp 1018 on a front facing
surface of collar 1012 to inwardly push a plunger 1020 of switch 285 after which a
detented depression 1022 of collar 1012 will provide a clicking feel and temporarily
retain plunger 1020 in its depressed position as can be observed in Figure 40. Plunger
depression activates intermediate work position switch 285 which then activates valve
141 to move rocker arm 1131. Reverse rotation of button 1287 and collar 112 allows
plunger 1020 to return to its nominal extended and deactivated position, via spring
biasing within switch 285. Plunger 1020 can return to the nominal position since there
is a gap between the plunger and an adjacent facing surface area 1022 of collar 1012,
as can best be seen in Figure 41.
[0043] Figures 38 and 39 show a lockout structure to block trigger depression unless the
buttons of intermediate switch assembly have been previously rotated to their intermediate
opening position. Edge 1014 of collar 1012 has a valley or catch 2030 which is openly
accessible in a downward direction. Each lateral wall of trigger 1279 further has
a matching ear 2032, with an arcuate upper edge, that is received within catch 2030
if the catch is in a rotational position above the associated ear, as viewed in Figure
39. This prevents depression of trigger 1279 and the associated switch. But when collar
is rotated to the position shown in Figure 38, ear 2032 is clear of catch 2030 and
the trigger is allowed to fully upwardly rotate to activate its jaw-closing switch.
[0044] While specific exemplary constructions and methods have been disclosed, other variations
may be employed. For example, different pneumatic (or less preferably, hydraulic)
fluid tube, switch and valve placement and actuation may be provided although some
of the advantages may not be achieved. In another example, a piston moved block may
have an internal camming slot with a pin-type follower; however, certain benefits
may not be realized. As another alternative, an electromagnetic (instead of the disclosed
fluid) actuator may be used with certain features, such as the intermediate switch
assembly and/or rocker arm features, among others. Moreover, both arms can pivot in
a different embodiment but such is likely more expensive and has a larger open packaging
size.
[0045] The foregoing description of the embodiments has been provided for purposes of illustration
and description. It is not intended to be exhaustive or to limit the disclosure. Individual
elements or features of a particular embodiment are generally not limited to that
particular embodiment, but, where applicable, are interchangeable and can be used
in a selected embodiment, even if not specifically shown or described. The same may
also be varied in many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be included within
the scope of the disclosure.
1. A clinching machine (41, 1041) comprising:
(a) a piston cylinder (75);
(b) a piston (241) moveable within the cylinder;
(c) multiple jaws (101, 59), at least one of which is moveable relative to the piston
cylinder;
(d) a workpiece clinching punch (225) mounted to one of the jaws;
(e) a workpiece clinching die (231) mounted to another of the jaws;
(f) a cam (251) moveable with the piston, between a retracted position and an advanced
position, to cause opening and closing of the at least one moveable jaw, the cam being
located between portions of the jaws when the cam is in at least of its positions;
and
(g) a rocker arm (131, 1131) rotatable about a pivot from a first rocking orientation
to a second rocking orientation independent of movement of the cam, the first rocking
orientation allowing the at least one moveable jaw to move to a fully open position,
and the second rocking orientation allowing the at least one moveable jaw to move
to an intermediate open position which is less than the fully open position.
2. The clinching machine of Claim 1, further comprising:
a fluid-operated moving jaw position valve (141);
a user-activatable, upper jaw position actuator (287, 1287) openly actuating the moving
jaw position valve; and
a spring (301) opening the at least one moving jaw to the intermediate open position
when the moving jaw position valve rotates the rocker arm to the second rocking orientation.
3. The clinching machine of Claim 2, further comprising:
a user-activatable trigger (279);
a main power switch (275), actuated by the trigger, causing fluid to advance the piston
and the cam which rotates the at least moveable jaw toward the opposite jaw to create
a workpiece clinch joint;
a cam follower (171, 1175) coupled to the moveable jaw; and
the cam being a wedge block with a peripheral camming surface against which the cam
follower rides.
4. The clinching machine of any one of Claims 1 to 3, further comprising:
a ring (97) located between the jaws on one side and the piston cylinder on an opposite
side;
a single piece and entirely polymeric handle (79, 1079) coupled to the ring, the handle
having a curved D-shape; and
a user-operable trigger (279) coupled to the ring opposite the handle;
wherein the clinching machine is hand-held and portable.
5. The clinching machine of any one of Claims 1 to 4, wherein:
the rocker arm is a lever including a forward end operably abutting a stop extending
from the at least one moveable jaw, and a rearward end coupled to a fluid actuator
located between the piston and the jaws;
a pivot of the rocker arm is between the ends of the rocker arm; and
axes of the rocker arm and a rotational pivot coupling the jaws, are parallel.
6. The clinching machine of any one of Claims 1 to 5, further comprising;
a hand-held spine (71);
one of the jaws operably rotating while an opposite of the jaws being stationary relative
to the piston cylinder;
the die being mounted adjacent a forward end of the stationary jaw and the punch being
mounted adjacent a forward end of the moveable jaw;
the stationary jaw being coupled to a forward end of the spine and the piston cylinder
being coupled to a rearward end of the spine;
an enclosed user-graspable handle (79, 1079) coupled to the spine and the stationary
jaw, the handle being wider than an exterior surface of the piston cylinder;
a piston rod (245) being linearly moveable within the spine;
a user-operable trigger (279) and an enclosed trigger guard (78) coupled to the spine
opposite the handle; and
the pivotable rocker arm being located between the forward end of the spine and a
rotational coupling between the jaws.
7. The clinching machine of any one of Claims 1 to 6, further comprising:
a moveable tail (151) coupled to an end of the moveable jaw opposite the punch;
a cam follower (171, 1175) coupled to the tail and operably contacting against the
cam when the cam is advanced to rotate the moveable jaw to a closed and workpiece
clinching position; and
a pin (157) including an offset lobe (159) which is rotatable to adjust an orientation
of the tail relative to the moveable jaw.
8. The clinching machine of any one of Claims 1 to 7, further comprising:
a piston return spring (247) partially located with an elongated and hollow spine
(71), the spine extending between the piston cylinder and a gimble ring assembly (53)
to which at least one of the jaws is coupled;
a channel extending along a length of the spine; and
a pneumatic tube (271, 273) routed in the channel.
9. A clinching machine (41, 1041) comprising:
(a) an actuator (241);
(b) multiple jaws (101, 59), at least one of which is moveable relative to the actuator;
(c) a workpiece clinching punch (225) mounted to one of the jaws;
(d) a workpiece clinching die (231) mounted to another of the jaws;
(e) a user-moveable trigger (279) operable to cause the actuator to move the at least
one jaw from a fully open position to a workpiece-clinching position; and
(f) a user-moveable button (287, 1287) operable to limit opening of the at least one
jaw to an intermediate open position which is less than the fully open position.
10. The clinching machine of Claim 9, further comprising:
a cam (251) moveable with the actuator, between a retracted position and an advanced
position, to cause opening and closing of the at least one moveable jaw, the cam being
located between portions of the jaws when the cam is in at least of its positions;
and
a rocker arm (131, 1131) rotatable about a pivot from a first rocking orientation
to a second rocking, the first rocking orientation allowing the at least one moveable
jaw to move to a fully open position, and the second rocking orientation allowing
the at least one moveable jaw to move to the intermediate open position.
11. The clinching machine of any one of Claims 1, 9 or 10, further comprising:
an elongated spine (71) which couples the actuator to the jaws;
the button being rotatable about an axis which is coaxial with the spine; and
the button and the trigger being located adjacent a forward end of the spine with
the trigger being moveable toward the spine.
12. The clinching machine of any one of Claims 9 to 11, further comprising;
an elongated and hollow, hand-held spine (71);
one of the jaws operably rotating while an opposite of the jaws being stationary relative
to the actuator;
the clinching die mounted adjacent a forward end of the stationary jaw;
the clinching punch being mounted adjacent a forward end of the moveable jaw;
a piston cylinder (75) coupled to a rearward end of the spine and the stationary jaw
being coupled to a forward end of the spine;
an enclosed user-graspable handle (79, 1079) coupled to at least one of the spine
and the stationary jaw, the handle being wider than an exterior surface of the actuator;
and
the user-operable trigger and an enclosed trigger guard coupled to the spine opposite
the handle.
13. A method of using a clinching machine (41, 1041), the method comprising:
(a) suspending the clinching machine from an overhead cable (89);
(b) manually grasping an enclosed handle (79, 1079) of the clinching machine to move
the clinching machine relative to a workpiece (43, 45);
(c) rotating a moveable jaw (101) to a fully open position;
(d) manually actuating a switch (141) to pneumatically rotate a lever (131, 1131)
between fully open and intermediate open positions;
(e) manually actuating a trigger (279) to pneumatically advance a piston (241) and
a block (251) attached to a leading end of a piston rod (245);
(f) rotating the moveable jaw to a fully closed and workpiece clinching position in
response to step (e);
(g) abutting the lever with a stop surface moveable with the moveable jaw to limit
opening rotation of the moveable jaw; and
(h) rotating the moveable jaw to an intermediate open position which is less than
the fully open position due to step (g).
14. The method of Claim 13, further comprising:
spring biasing the moveable jaw toward the open positions;
spring biasing the piston toward a retracted position; and
placing an entire user palm inside the handle which is a single piece and entirely
polymeric curved handle of the clinching machine, the handle being on an opposite
side of the piston rod from the trigger.
15. The method of any one of Claims 13 or 14, further comprising:
manually rotating a shaft (157) to adjust a full opening end of travel position of
the moveable jaw relative to an opposed stationary jaw;
a clinching die (231) mounted to the stationary jaw;
a clinching punch (225) mounted to the moveable jaw;
moving a tail (151) coupled to the moveable jaw by adjusting the shaft; and
engaging a cam follower (171, 1175) with a camming surface of the block, the cam follower
being mounted on the tail.